Box for storing and dispensing cable

ABSTRACT

A box for storing, shipping and dispensing cable or wire from a spool contained within the box. The box having features to allow efficient dispensing of cable in measured amounts.

[0001] This application claims the benefit of Provisional Application No. 60/262253, filed Jan. 17, 2001.

FIELD OF THE INVENTION

[0002] The present invention relates to a box construction designed to contain a spool of wire or cable for smoothly dispensing such wire or cable in measured amounts.

BACKGROUND OF THE INVENTION

[0003] It is common today to sell wire and cable for industrial and commercial use mounted on spools. The spools generally have a drum-like configuration. However, such a spool shape alone is not always convenient for feeding measured amounts of cable. In addition, spools provide no substantial protective covering for the cable, nor do they provide an omni-directional, stable, stackable package. Additionally, conventional spool packaging heretofore in use is comparatively expensive to make an is at a competitive disadvantage in sales against wire sold without being spool wrapped.

SUMMARY OF THE INVENTION

[0004] Embodiments of aspects of the present invention provide an improved apparatus for storing and dispensing cable or wire.

[0005] One illustrative embodiment of the invention provides a simple packaging system for wire or cable that permits wire or cable to be stored safely with the cable protected, while at the same time permitting measured amounts of the cable to be fed from the spool for subsequent use. It is noted that the terms wire and cable are used interchangeably herein.

[0006] In another illustrative embodiment of the invention a simple packaging system is provided for wire and cable that facilitates the installation of cable under a wide range of conditions. In particular, the present invention provides a convenient means for storing and moving cable and at the same time permits the easy pay out of measured amounts of cable in a manner which is efficient to a cable installer.

[0007] An advantage of the present invention is that it provides a means for storing cable in a relatively inexpensive package designed to support cable on a spool.

[0008] A further advantage of an embodiment of the present invention is to provide an improved means of paying out cable at a steady rate, avoiding tangling and backlash of the cable.

[0009] In yet another illustrative embodiment of the invention, a box for dispensing cable is provided. The box comprising a pair of opposed, rectangular side walls, a front wall adjacent to each of the pair of side walls, a back wall adjacent to each of the pair of side walls and opposite from the front wall, a top wall adjacent to each of the pair of side walls, with the front wall and the back wall and a bottom wall adjacent to each of the pair of side walls and opposite the top wall. The box also includes a panel in a wall of the box adapted to be displaced to provide an opening in the wall with a cable spool support located in the box. The cable spool support includes journals to support a spool of cable for dispensing cable from the spool in the box. One embodiment is formed entirely of cardboard, folded in a manner to provide a pair of opposed sturdy journals.

[0010] Further features and advantages of the present invention, as well as the structure and operation of various embodiments of the present invention are described in detail below with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The invention is described with reference to the following drawings, in which similar reference numbers indicate similar structures.

[0012]FIG. 1 is a perspective view of a cable box showing an embodiment of the invention as it would be received by a user;

[0013]FIG. 2 is a perspective view of the embodiment of FIG. 1, with cable being dispensed from a large opening;

[0014]FIG. 3 is a perspective view of the embodiment of FIG. 1, with cable being dispensed from a handle opening;

[0015]FIG. 4 is a perspective view of a spool of cable positioned on two internal components of an embodiment of the invention forming journals for the spool;

[0016]FIG. 5 is a plan view of a die cut single sheet of cardboard used to construct a box and rigid supports;

[0017]FIG. 6 is a cutaway view showing a box and rigid supports forced from a single sheet of cardboard;

[0018]FIG. 7 is a perspective view of the invention, showing a first flap of the top wall in a closed position and a second flap of the top wall in an open position;

[0019]FIG. 8 is a perspective view of the invention, showing both the first flap and the second flap of the top wall in an open position;

[0020]FIG. 9 is another view of the invention, showing a cable retainer forming a part of the invention;

[0021]FIG. 10 is a view of yet another aspect of the invention, showing a integral cable lock.

DETAILED DESCRIPTION OF THE DRAWINGS

[0022] The present invention will be better understood upon reading the following detailed description of various embodiments of aspects thereof in connection with the drawings.

[0023] The present invention comprises a box preferably formed of heavy duty corrugated cardboard or other relatively stiff cardboard or other material which is rugged, capable of supporting heavy contents, and typically used for shipping spools of wire and cable. Cardboard is generally preferred because it allows the box to be made at a lower cost. The box is preferably formed as a six-sided container having a rectangular side wall 1 and an opposite side wall of equivalent dimensions and parallel to it, as well as front wall 2 with a corresponding parallel back wall at the other end, and a top wall 3 with a corresponding bottom wall parallel thereto. The box may be conveniently formed with the top 3 being a lockable cover. The front wall 2 illustrated in FIGS. 1 and 2 is formed with a die-cut, removable panel 10 which can be removed along a perforated line 10A. A portion 10B of the panel 10 may be folded inwardly along crease line 10C within the box lying adjacent to the spool 26 of cable. This may be done such that the panel 10 frictionally engages the spool 26 or such that the panel 10 serves to reinforce the upper edge of the opening 11 which may be used as a handle for the box. The edges of the panel 10 may be conventionally die cut intermittently so that it will remain in planar alignment with the wall 2 unless moved relative thereto under a positive force. The upper edge may be scored or die cut depending on whether the panel is to be removed completely or folded inwardly.

[0024] The top 3 of the box is also provided with a die-cut opening 15 forming a handle grip. The die-cut handle opening 15 extends laterally across the top of the box and may be provided with an enlarged center-cut segment 16 for ease in removing the portion of the top 3 to form the handle opening 15. This center-cut section may also be used to dispense cable without removing the die cut portions of the handle as is shown in FIG. 3. It may alternatively be diecut in a similar fashion to panel 10 with only one side forming a large scored section.

[0025] The relative dimensions of the box are best illustrated in FIG. 2. For example, when used for a conventional spool of electrical wire sold for industrial or installation purposes in bulk, a box suitable for on site installations may comprise a box with outer dimensions on the order of 8″ wide, 14′ long and 14½″ high, respectively represented as dimensions A, B and C in FIG. 2. These outer dimensions may, of course, vary depending on the precise size of the spool to be contained. The panel 10 should preferably have dimensions on the order of about 8″ long and 5½″ wide, respectively shown as dimensions F and G in FIG. 2. The handle opening 15 may vary in size depending on the size of the spool but preferably should be 5½″ wide and about 2″ deep as represented by D and E in FIG. 2.

[0026] Positioned within the box is an interior support, with its relative position within the box illustrated in FIG. 4. The interior support is preferably formed of two opposed rigid supports 18. These rigid supports 18 may comprise STYROFOAM (expanded plastic made from polystyrene) or other rigid plastic elements made through a molding, blow forming, or other plastic forming process. Alternatively, the rigid supports may also be comprised of internal panels of cardboard that may be integrally formed from the same sheet of cardboard used to form the box. The supports are positioned parallel to one another on the inner surfaces of the side walls 1 in a spaced relation. Each support is formed of board approximately one inch thick in the embodiment illustrated in FIG. 4, with length and width dimensions sized to occupy the width and height of the box. In the illustrated embodiment, the supports here are “U”-shape. The supports 18 are each formed with an integrally defined journal to function as an axle or spindle support 20 in the preferred embodiment. The spindle supports 20 are formed as an elongated opening extending from the upper edges of the supports 18 downwardly from the top 3 of the box towards the bottom edge of the box. The edges 22 form the side edges of the journals while the bottoms 23 forms the bottom edges of the journals. In the illustrated embodiment, the journal of each support is defined by the bight of the “U”-shape. The edge 22 is positioned closer to the bottom of the box than to the top of the box. By spacing the facing edges 22 a distance on the order of five inches apart, a variety of different sized spindles for spools 26 of wire and cable may be accommodated. A spool 26 of wire or cable 25 is conventionally formed with a spool 26 supported on a spindle 24 with the spindle 24 preferably integrally formed within the spool and having a diameter of less than five inches or less than the space between the opposite edges 22 of each side 18. Alternative embodiments may incorporate a spool that is separate from a spindle.

[0027]FIG. 5 illustrates a plan view of one embodiment of the invention where both the box and the rigid supports 18 are formed from one sheet of cardboard. The figure shows the sheet of cardboard after it has been cut but before it has been glued and folded to form a box with integral rigid supports. The rectangular side walls 1, the end wall 2, and the top wall 3 are numbered in FIG. 5 such that they correspond to the numbered sides shown in FIGS. 1, 2, and 3 which show a box in the assembled state. Solid lines in this drawing represent complete cuts in the cardboard while dashed lines represent either fold lines or perforation lines where panels may be removed if desired. FIG. 6 shows a cutaway view of box formed from the sheet of cardboard shown in FIG. 5. To form the box, the following steps are taken. The sheet is folded along crease lines 2A, 1A between the panels defining the front 2, the back, the side walls 1, and the bottom. Then too, 41A forming a portion of the bottom is glued to tab 41B, 42A is glued to tab 42B and 43A is glued to tab 43B. Tabs 41A, 41B, 42A and 42B form the bottom when secured together. The sheet now has an elongated box form without a top. The next step involves folding panels 44 which are connected to the upper edge of the side panels 1 by crease lines 44A and folding them into the internal cavity of the box. These internal panels 44 as illustrated in FIG. 5 each have spacers 46 that integrally connect along crease lines 44B along the edges remote from side panel 1. Each spacer 46 includes a center section 46A and end sections 46B and 46C. The end sections are connected to the center sections along crease lines 46D. These end sections 46B and 46C are folded over the center section 46 into a sandwich-like configuration. Thus assembly of the sandwich-like configuration is folded against the internal panel 44 between the panel 44 and the side wall 1. When so folded the unfolded longitudinal edge of the sandwich-like configuration is aligned with the lower edge 50 of rectangular opening 51. When assembled the configuration provides a rigid formal support 52 as illustrated in FIG. 6, having at least four thicknesses of cardboard that will function to support the spindle of a spool of wire. FIGS. 7 and 8 illustrate the details of the top wall 3 of the box. The top wall provides a secure means to keep the box closed and also improves the structural rigidity of the box. The top wall 3 includes a first top flap 31 and a second top flap 32. To close the lockable cover, the first flap 31 is moved into the position shown in FIG. 7. Here, the tab at the distal end of the first flap is tucked into an interior portion of the box. Next the second flap 32 is folded over the first flap to a position like that shown in FIG. 1. The three flap locks 34 are then tucked into an interior position of the box. The three corresponding locking tabs 35 are then placed through the flap locks 34 to hold the top wall 3 rigidly in place. Such a rigid connection is particularly important when a handle is included in the top wall 3 of the box. Various locking tabs may be incorporated through the invention to hold the various components in place.

[0028] As illustrated in FIGS. 2 and 3, the spool 26 with the cable 25 is pre-packaged within the box. The free end of the cable 25 may be drawn or fed from the box either through the handle opening 15 as illustrated in FIG. 3 or, alternately, through the large opening 11 as shown in FIG. 2, depending upon the particular needs and desire of the user of the box. FIG. 7 shows a retainer that may be used to hold the free end of the cable 25 in place during shipment. The retainer is an elongated rubber band 17, but alternatively could be comprised of different materials including an elastic fabric, a non-elastic fabric, a plastic material, a cord or any similar materials know to those in the art. A first end 17A of the band is fastened to the cable approximately 6 inches from the free end 25A of the cable 25. A second end 17B of the band is then stretched around the spool in the same direction as the cable. After one complete revolution, the second end is looped around the free end of the cable which serves to lock the free end in place. The band has the added benefit of making the free end of the cable easy to located and remove. To remove the cable from the box, one only has to locate the band and pull or rotate it until it leads to the free end of the cable. Pulling the band in the vicinity of the cable free end allows the second end of the band to free itself from the cable. A continued pulling force will cause the spool to rotate until cable is being dispensed. Once cable has been dispensed, the band can easily be removed from the cable.

[0029] One aspect of the invention includes a cable lock 19 that can be used to hold the free end of the cable. This lock 19 is illustrated in FIG. 10. The lock would likely be used when only a portion of the cable in the box has been dispensed and the remaining portion is stored. In such a situation, the free end of the cable is wedged between the die cut handle opening 15 and the corresponding portion of the box. The wedging action locks the cable in place until it needs to be dispensed again.

[0030] While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, embodiments of the invention as set forth herein are intended to be illustrative, not limiting. Various changes may be made without departing from the invention. 

What is claimed is:
 1. A box for dispensing a length of cable wound around a spool positioned in the box comprising, a box having continuous opposite sides, opposite ends and a top and bottom, an opening in one end wall, and means forming a handle grip in the box, and a cable spool support positioned within the box and including opposed rigid supports parallel to one another and shaped to support opposite ends of a spindle upon which cable is wound with the free end of the cable extending outwardly of the box.
 2. A box for dispensing cable, the box comprising: a pair of opposed, rectangular side walls; a front wall adjacent to each of the pair of side walls; a back wall adjacent to each of the pair of side walls and opposite from the front wall; a top wall adjacent to each of the pair of side walls, the front wall and the back wall; bottom wall adjacent to each of the pair of side walls and opposite the top wall; a panel in a wall of the box, adapted to be displaced to provide an opening in the wall; and a cable spool support located in the box, the support including journals to support a spindle of a spool of cable for dispensing cable from the spool in the box, wherein the cable spool support comprises a pair of rigid supports positioned adjacent opposite walls and each closely fitting at least portions of five walls, each of said supports including a journal integrally formed in the support and shaped to receive an end of a spindle supporting a spool of wire, said spool of wire including a spindle, with the spool positioned between the supports one from the other, the end of the wire on the spools removable from the box through said opening.
 3. The box as set forth in claim 2 wherein each of the pair of rigid supports are made of cardboard.
 4. The box as set forth in claim 3 wherein the box and each of the pair of rigid supports are formed from a single sheet of cardboard.
 5. The box as set forth in claim 2 wherein each of the pair of rigid supports have a U-shape, with the journal of each support defined by the bight of the U-shape.
 6. The box as set forth in claim 2 wherein each of the pair of rigid supports are comprised of an expanded polystyrene plastic.
 7. A box as set forth in claim 5 having a panel in one of the front or back walls, said panel shaped and sized to be moved from a position in a plane common with the front or back wall to a position at least in part engaging the cable on the spool.
 8. A box as set forth in claim 7 wherein said panel is adapted to be folded along a line intermediate the ends and to be hinged along a parallel line for movement from and to said plane.
 9. A box as set forth in claim 3 wherein each of said rigid supports comprise an internal panel integrally connected to the upper edge of a side wall and folded inwardly against the inner surface of said side wall.
 10. A box as set forth in claim 9 wherein the internal panel is formed with an opening having a lower edge that extends transversely across a portion of the internal panel at a spaced distance from the lower edge of the side wall forming a supporting surface for an end of the spindle.
 11. A box as set forth in claim 10 having spacers integrally connected to the lower edge of the internal support and folded between the internal support and side wall to form a reinforcing member for said supporting surface. 